EXPERIMENTAL ANALYSIS OF AN ETHANOL

BLENDED GASOLINE IN A FUEL INJECTED

SPARK IGNITION ENGINE

by

ALOK KUMAR

Centre for Energy Studies

Submitted in fulfillment of the requirements of the degree of

DOCTOR OF PHILOSOPHY

to the

INDIAN INSTITUTE OF TECHNOLOGY, DELHI

MAY, 2008
 CERTIFICATE

The thesis entitled, "Experimental analysis of an ethanol blended gasoline in

a fuel injected spark ignition engine" being submitted by Alok Kumar to the

Indian Institute of Technology, Delhi, for the award of doctor of philosophy is a

record of bonafied research work carried out by him. He has work under our

guidance and supervision and has fulfilled the requirements for the submission of

this thesis, which has attained the standard required for a Ph.D. degree of the

institute. The results presented in the thesis have not been submitted, in part or

full, elsewhere for the award of any degree or diploma

We certify that he has pursued the prescribed course of research.

Date:

Prof. M.K. Gajendra Babu Dr. D.S. Khatri

Centre for Energy Studies Director, Harit Energy Solutions

Indian Institute of Technology, Delhi Faridabad, Haryana
NEW DELHI 110016

iii
 ACKNOWLEDGEMENTS

No Herculean task can be accomplished without the support and contribution of

number of individuals. These few paragraphs are an effort to epitomize my
gratitude towards all those who have helped me directly or indirectly to complete
my research work successfully.

It is my great privilege to express my deep sense of gratitude to my supervisors,

"Prof. M.K. Gajendra Babu, Centre for Energy Studies, and Dr. D.S. Khatri,
Director, Harit Energy Solutions", for their continuous panegyric efforts, ever
helping attitude, throughout critical and valuable suggestions, guidance and
constant inspiration with a keen interest in the progress of present research and
bringing this work to completion. Their valuable word of solace and
encouragement, especially during difficult times are ever remembered. I am
forever heartedly indebted to them.

I am extremely thankful to Prof. L.M. Das, Prof. M.G. Dastidar, Prof. T.S.
Bhatti and Prof. J.P. Subramanyam for their valuable suggestions and constant
encouragement throughout my research work.

With sense of gratitude and great pleasure, I acknowledge the whole hearted co-
operation extended by Mr. Shashi Singh, Managing Director and Mr. Markus
Feichtner, Executive Director, AVL Technical Centre Pvt. Ltd, Gurgaon during
my entire research work. I also acknowledge Mr. P.T. Deo and all colleague of
AVL Technical Centre Pvt. Ltd, Gurgaon, for their valuable suggestions and
encouragement during tenure of this research work. I am very grateful to the
management of AVL, Technical Centre Pvt. Ltd. for permitting me to carryout this
research work.
There are also some friends and colleagues who have helped me along the way
for the successful completion of this work. Firstly, I would like to thank Mr. Manoj
Athawe for his kind co-operation and support during critical phase of work. I also

V
thank all the colleagues and research scholars of CES, IIT Delhi, for providing
very good company throughout this work.

Mr. G.P. Singh of Engines and unconventional Fuels Laboratory along with his
staff have provided solid technical support during the course of experimental
work. Their matured suggestions during the experimentation were quite
appreciable.

My special thanks to Mr. Amit Gupta and Mr. R.K. Gupta of Interface Micro
System, Gurgaon; for providing necessary support to develop stepper motor
controller. I would also acknowledge VIALLE alternative fuel systems for
providing stepper motor and relevant information.

Due to preoccupation with the priorities of the research work, my mother, wife
and daughter were deprived of the privileges and prerogatives which either the
society or nature has bestowed on them. To them, I am very much indebted.

At last but not least, thanks to God and all my well- wishers, which do not figure
in this acknowledgement, however have helped me in tenure of research work.

New Delhi Alok Kumar
May 2008

vi
 ABSTARCT

Depleting reserves of fossil fuels and the increasing environmental pollution

caused by burning of fossil fuels have increased the worldwide demand for
renewable and cleaner fuel. Taking into account, the production from
renewable sources, the most attractive alternative fuel for gasoline engines
seems to be ethanol. When blended with gasoline, the physico-chemical
properties of the blend changes and in turns affects material compatibility,
engine performance and emission characteristics.

In present investigation, a literature survey was conducted to identify the

potential and challenges of ethanol as S.I. engine fuel. Experimental
investigations were carried out for increased utilization of ethanol, without
affecting performance as compared with 100% gasoline operation. An online
fuel blending system was designed and developed to vary ethanol percentage
in the gasoline. This online fuel blending system helps to address various
problems associated with ethanol such as cold start, storage, water
separation and higher substitution of ethanol in the blend.

The combustion analysis carried out with different ethanol-gasoline blends

shows the need for optimization of engine operating parameters for better
performance and improved emission characteristics. Comprehensive
investigations were carried out with low (E10), medium (E30) and high (E70)
ethanol percentage in the gasoline. The results obtained before and after
optimization were compared to justify the modifications carried out in the
existing engine to harness the maximum potential with different blends.

vu
The results obtained show that with online fuel blending system:

• The problem of cold start with ethanol can be completely

eliminated.

• The risk of water separation and the problem associated with

storage of pre-blended fuel can be eliminated.

• Ethanol blended in low percentage (E10), does not require any

major modification in the existing engine. However with middle
and high percentage ethanol addition calls for certain engine
operating parameters to be modified for better performance and
emission characteristics.

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 CONTENTS

Page No.

Certificate
Acknowledgments
Abstract v
Contents vii
List of Figures xi
List of Plates xvii
List of Tables xix
Nomenclature xxi

Chapter: 1 INTRODUCTION 1-8

1.1 General Background 1

1.2 Brief History of Alcohol Fuels 2
1.3 Ethanol As a Fuel 3
1.4 Socio-Economic and Environmental Aspects of Ethanol 4
1.5 Other Alternative Fuels 5

Chapter: 2 LITERATURE SURVEY 9-20

2.1 Introduction 9
2.2 Physico-Chemical Characteristics of Various Fuels 9
2.3 Purity Criteria of Ethanol for Blending 10
2.4 Material Compatibility 11
2.5 Cold Start Behavior 12
2.6 Engine Performance and Emission 14
2.7 Engine Durability 19
Chapter:3 CONCLUSION FROM LITERATURE SURVEY AND
21-24
NEED FOR PRESENT WORK
3.1 Summary of Literature Survey 21

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 Page No.

3.2 Need For Present Work 22

3.3 Motivation and Objective 24
DESIGN AND DEVELOPMENT OF EXPERIMENTAL
Chapter:4 TEST SET-UP AND ONLINE FUEL BLENDING 25-38
SYSTEM
4.1 Introduction 25
4.2 Experimental Test Set Up 25
4.2.1 Single Cylinder Gasoline Research Engine 27
4.2.2 Eddy Current Dynamometer 28
4.2.3 Gravimetric Fuel Balance 29
4.2.4 AVL 619 Indicating Equipment 30
4.2.5 Crank Angle Encoder 31
4.2.6 Pressure Transducers With Charge Amplifiers 32
4.2.7 Portable Exhaust Gas Analyzer 33
4.2.8 Temperature Sensors 33
4.3 Design and Development of Electronically Controlled
34
Online Fuel Blending System
4.3.1 Overall Description of the Blending System 34
4.3.2 Selection of Stepper Motor 35
4.3.3 Design of Electronic Controller for Stepper Motor 36
Chapter: 5 RESULTS AND DISCUSSIONS 39-96
5.1 Introduction 39
5.2 Comparative Analysis of Basic Properties of 39
Experimental Fuels
5.2.1 Effect on Fuel Volatility; V/L ratio, Reid Vapor Pressure 41
5.2.2 Effect on Heat of Vaporization 43
5.2.3 Enleanment Effect of Ethanol 44
5.2.4 Effect on Octane Number 46
5.2.5 Effect on Fuel Economy 46
5.3 Basic Reference Test and Optimization of Engine
Operating Parameters with 100% Gasoline 46

Page No.

5.4 Effect of Different Ethanol Blend on Engine

Performance and Emission without Modifying any 52
Operating Parameter, Tuned for 100% Gasoline
Operation
5.5 Optimization of DOI and Ignition Timing with Different
Ethanol Gasoline Blend (El 0, E30 and E70 60

5.6 Analysis of Combustion, Performance and Emission 67

with Optimized Engine Operating Condition
5.6.1 Combustion Study 67

5.6.2 WOT Performance After Optimization 74

5.6.3 Effect on Exhaust Emission After Optimization 77

5.6.4 Comparison of Performance and Emission Before and 80

After Optimization
5.7 Comparison of Performance and Emission of 85
Experimental and Simulated Investigation

Chapter: 6 CONCLUSIONS 97-100

6.0 Conclusions 97

References

Appendices

Appendix-I: Basic Engine Data

Appendix-II: Eddy Current Dynamometer Specification

Appendix-III: Technical Data for Indicating Equipment

Appendix-IV: Technical Data for Crank Angel Encoder

Appendix-V: Technical Data For Pressure Transducer

And Charge Amplifier

Appendix-VI: Technical Specification of AVL Exhaust

Gas Analyzer

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